Machinery showcase

22 September 2009



The PPMA Show 2009 will take place at the NEC, Birmingham, on 29 September - 1 October


In the words of group exhibition director Ian Crawford, the PPMA Show is “the perfect showcase for the UK’s processing and packaging industry suppliers”. As he says: “Even in tough economic times, there are still many companies in the UK and overseas with a genuine interest in sourcing and buying machinery and equipment, and an exhibition like the PPMA Show provides the best forum for them to discover the latest innovations and technologies.”

Here, we take a look at some of those innovations and technological developments that will be on display at the show.

Adhesives

New from leading UK producer of hotmelt adhesives Beardow Adams (stand G63) are high heat resistant and fast setting variants of the company’s BamFutura packaging range – said to be ideal for high speed lines, particularly cartons running at speeds of more than 200/min. In common with all BamFutura hotmelts, the use of high quality raw materials in these new products is said to eliminate the odours and fumes in the production process associated with traditional hotmelts. As a result, they do not taint foodstuffs.

Introduced to the Beardow Adams labelling range is another clean running hotmelt – BAM 1726, a high tack grade for labelling carbonated drinks onto PET bottles, where its cohesive strength is said to cope with the expansion of bottles that are shaken or become warm. It can be used on a wide variety of labelstocks and containers.

Capping and closing

Holmach (stand E20) will launch a new version of Antonio Mengibar’s trigger pump capper. Mengibar has been at the forefront of trigger and pump capping for personal, household and chemical products for over 20 years. There are over 20 high speed installations in the UK alone.

The latest unit allows unscrambling, sorting and capping of trigger and dosing pumps at speeds up to 250 bottles/min. It is of modular design, allowing companies to upgrade the machine as their production volumes increase. With hand feeding at speeds from 40 bottles/min, the machine can be retro fitted with additional heads, automatic sorting and trigger feeding allowing eventual speeds of more than 150 bottles/min, without the need for any operator intervention.

All types of trigger and dosing pumps can be used, with simple change-over between trigger pump capping and ‘normal’ screw or press capping for standard containers or re-fill packs.

As well as capping, this exhibit will include new patented filling technology said to eliminate the need for complicated ‘bottom-up’ filling. The Low Reynolds nozzles eliminate moving parts within the product flow, allowing even highly foaming products, such as alloy wheel or window cleaning chemicals, to be filled quickly without foaming.

PFM Packaging Machinery (stand E30) is staging the world launch of a new reclosure system for flexible packaging, pictured above. The BG4800 EWL high speed MAP flow-wrapper will be demonstrated, configured specifically to produce the Plix-Pack bags by attaching PE tape moulded with tiny hooks that mate to reclose the top of the bag.

This approach is said to combine the strength and life of a zipper profile with the ease of use of adhesive based systems. Applications cover perishable products, such as cheese, sliced cooked meats, snacks and petfood, as well as loose hardware items such as nuts and bolts.

“The tape re-seals onto itself hoo-kto-hook over a typical width of 10 mm, which makes alignment extremely easy,” explained PFM sales and operations director Chris Bolton. “Reclosure is simply a matter of pressing the bag top back together with no need to line up the front and back accurately.”

The BG4800 EWL flow-wrapper operates in the same way as a Tiny hooks mate to reclose the top of PFM’s Plix-Pack bag conventional MAP unit but with the longitudinal seal made at the side where the Plix-Pack profiles are also attached to the inner faces. Multiple cross-sealing jaws set around a cam wheel provide higher dwell times for maximum seal security.

Plix-Packs can also be made on vertical PFM bagging machines and with patches instead of strips of tape, providing a more durable alternative to self-adhesive labels used for bag reclosure. Tobacco pouches and packs of pasta, coffee and rice are among examples of suitable uses.

Coding and marking

Allen Coding (stand E61) is to feature a ‘high performance, low cost’ thermal transfer printer said to be versatile enough for printing fixed and variable data, text and graphics. The Model 53LTi is also claimed to be ideal for reproducing barcodes, real-time, sell-by dates, batch numbers, prices, source codes ‘and much more’. It has a 53 mm x 30 mm print area, print speeds of up to 250 mm/sec, and a 600 m ribbon capacity with cassette loaded ribbon.

The new A-Series plus Duo range of continuous inkjet (CIJ) printers to be demonstrated by Domino (stand C11) are said to be able to match the throughput levels demanded by high speed canning/bottling lines. Based on the proven reliability of Domino’s A-Series range (over 100,000 installations worldwide), the plus Duo employs a special new twin-jet printhead with what the company says is a ‘revolutionary’ new compact gunbody design to achieve its high performance.

Interactive Coding Equipment (ICE) (stand E40) will launch the latest version of its Clarity operating system for its proven range of Zodiac thermal transfer overprinters and Torus high definition inkjet printers.

The new Clarity features several enhancements. To minimise running costs, the Zodiac has a number of ribbon save modes as standard to reduce the cost per print. This has been augmented with the latest version of interleaved radial ribbon save. When overprinting a radial print on a flowwrapper, for example, competitive thermal transfer printers can waste as much as 80% of the ink ribbon. Radial ribbon mode can automatically move and now interleave multiple prints to provide a five-fold reduction in cost per print with no degradation of print quality, it is claimed.

Also, a new printer cloning feature available in Clarity allows the complete printer configuration to be saved directly onto a USB-key (memory stick), so that if new or replacement equipment is installed, it can be used to quickly produce a clone to minimise downtime and increase the speed of commissioning for new equipment. Maximum uptime is also assured with the new Zodiac print sensor logic, which compares encoder input information (speed) and inputs from the host packaging machine to identify faults such as incorrect installation or a break in the packaging web to be overprinted.

New from Markem-Imaje (stand D10) is the SmartDate 5/128 coder, said to bring exceptional levels of versatility to large format thermal transfer printing. It can be switched between intermittent or continuous modes, and configured for either left or right-handed operation. Like others in the range, it offers users a choice of control options – colour touchscreen, classic controller or web browser based integration.

For intermittent operations such as bagging and labelling, the SD5/128 has a 128 x 75mm print area, and in continuous mode prints up to 128 x 150mm on flow-wraps, sachets and pouches. This offers a number of cost saving opportunities. Users can print large amounts of variable information, in addition to the usual date and batch codes, so that packaging materials can be rationalised and costs reduced. Rather than use two coders to mark top and bottom or both sides of a pack, a single SmartDate 5/128 can generate multiple prints in the same cycle. Typical applications include ingredients listings, nutritional data and extended product details.

Filling

A ‘revolutionary’ new modular packaging machine concept promises to maximise Ilapak (stand C20) users’ return on investment. The modular concept Carrera 4000 is the first of the company’s new range of horizontal packaging machines that, it says, will lower customers’ operating costs per pack by achieving optimum levels of packing flexibility, machine specification and performance throughout the life of the machine. The modular concept allows customers to define their machine’s specification and performance at the time of purchase and then to revise their specification throughout its life, ‘at minimum cost’.

Key features of the company’s latest software platform incorporated in the Carrera 4000 include a user friendly touchscreen HMI for minimising operator error; an electronic control platform with internet connection for remote servicing and monitoring of customer machines; as well as software to predict component failures in advance and the ability to minimise energy and material consumption.

The new machine also incorporates energy saving features such as the use of energy recuperation systems in the motor drives, while its hygienic design is said to be consistent with the highest standards.

Also new is the open-frame Vegatronic 4000 vertical form, fill and seal machine, capable of producing Amcor’s PushPop easy to open, standup packs. The continuous film motion machine will handle an exceptionally wide range of pack styles, including Quattro, Doy-style stand-up packs, and standard pillow packs for numerous applications such as cheese, produce, confectionery, savoury snacks and nuts.

A new range of equipment from Riggs Autopack (stand C11) has been designed specifically for opening, filling and sealing stand-up plastics pouches for the food industry. This compact, mobile, stand-alone unit is said to provide efficient and damage-free depositing of hot or cold products and to be ideal for liquid or semi-liquid foods such as soups, sauces, marinades, pastes and pestos.

Claimed to be ‘a fraction of the cost of a fully automatic alternative’, the system can be used by a single operator and can be adapted to handle plastics pots, tubs and jars, giving it exceptional flexibility for smaller businesses.

Also on the stand will be a selection of the company’s semi-automatic depositors and indexing conveyor systems, for depositing liquids, pastes or solids in suspension into glass jars, bottles, plastics pots, tubs, buckets and ready meal trays.

The latest addition to the Rovema (stand D30) VPI Series of intermittent motion vertical baggers, the compact VPI-180 can be used for many different products. Pillow style bags can be produced with a flat bag width from 50-180mm and gusseted pillow style bags and flat bottom style bags up to a flat width of 220mm. The machine has a top speed of 240 cycles/min in Twin execution and can have different feed systems on each filling tube – for example, one side can run volumetric and the other an auger.

Rovema will also feature its VPL260R for Doypacks with low drop height. This model will run at speeds of up to 120 packs/min on a vertical machine with the pack formed in the film reel carriage, ensuring a low drop height for the product. It can also run pillow packs at up to 200/min, and with change parts can run stabilo and flexcan bags as well as Amcor Pushpop.

The jaws run with the film and the distance can be programmed on the display up to 200 mm, allowing a wide range of thin and heavy films to be run. The machine can also run euro slot on the Doypack.

Overwrapping

The recently introduced Evo-Fold overwrapper to be exhibited by Marden Edwards (stand C81) has been designed as an entry level, fully automatic machine for medium speed applications. Typical uses include the wrapping of tea, confectionery, cosmetic and pharmaceutical products.

The Evo-Fold is said to compete directly with automatic shrinkwrapping machines for price with the extra benefits of reduced energy consumption, use of low cost films and a high quality wrap and seal. To demonstrate its versatility, the machine will be wrapping with both a BOPP clear film and a newly introduced, fully biodegradable heat sealable paper. Wrapping with heat sealable paper instead of film provides the product with a high quality, gift wrapped appearance as well as protecting it.

According to Marden Edwards, advances in component manufacturing technology mean the Evo-fold has a higher specification than many more expensive machines on offer and, while it is the company’s ‘entry level’ machine, it can perform to levels seen previously only on more sophisticated equipment.

Pallet wrapping

PPMA 2009 has been chosen by Omega Packaging Machinery (stand B33) for the debut of a new pallet wrapper claimed to cut the time and cost of palletising dramatically and improve its environmental footprint.

The traditional protective board ‘top hat’ and base, board sheets and strapping in a single prepared pallet cost around £4, says Omega. Instead, its new machine automatically inserts foam around the top and base of the pallet, delivering improved protection for
approximately 60p per pallet. “A company sending out 2,000 pallets every month would save over £6,500 each month in packaging costs alone,” the company stated.

Whilst it takes, on average, three minutes for experienced personnel to apply packaging materials by hand to a conventional pallet so that it is ready for transport, Omega’s automated wrapper is claimed to take approximately 45 sec. By eliminating the need for board, the foam edge protection ensures the load is stable, secure and well protected, in addition to the labour saving benefits of an automation system and having UK sourced spares readily available.

The new Omega machine is also said to be environmentally friendly – both the stretch film and the foam are 100% recyclable. In addition, the end user no longer has to separate the packaging – the foam and film can be put into the same skip and the board sheets re-used.

UK distributor for a wide range of packaging equipment from leading manufacturers Friedheim International (stand F40) will exhibit with Germany’s Beck Packautomaten and Pfankuch Maschinen. The main feature of the stand will be a specially created production line comprising Beck’s Multiplex Pico fully automatic film wrapping machine with linked shrink tunnel, which will be wrapping Blu-ray boxes being fed by the Pfankuch Model PSA 450-G vacuum shuttle feeder.

In addition, Pfankuch’s ASB 175KBNA feeder head ‘bottleneck applicator’ will be demonstrating the placing of promotional bottleneck hangers onto a revolving conveyor of plastics bottles.

Visitors to this exhibit will also be able to gather information on equipment available from Friedheim International’s other packaging suppliers: Audion Elektro (standalone shrink wrapping machines) and Iman Pack (horizontal and vertical form fill seal machines, wet wipe and dry wipe machines, and vertical and horizontal wrappers).

Checkweighing and metal detection

Food products can be checked for metal contaminants ‘with unprecedented sensitivity’ with the new THS/MS21 metal detector being launched by Constant Instruments (stand D82). With a With a sensitivity up to 30% higher than for earlier models, the instrument is said to detect contaminant particles at high speed even in difficult, highly conductive products containing high levels of salt or fat.

“The new multi-spectrum models provide inspection standards until now only seen in the pharma industry,” says Constant’s managing director, Leslie Hunt.

Fortress Technology (stand D100) will highlight its Phantom range of ‘high performance yet cost effective’ metal detection systems for the food, pharmaceutical, products, together with a complete British Retail Consortium (BRC) accredited Vector integrated conveyor system. Fortress’s Contact data logging communication software for improved report generation will also be shown.

Visitors to the Loma stand (E81) will see the next generation CW3 checkweigher and IQ3 metal detector combination machine.

The ‘compact and versatile’ CW3 combined checkweigher and metal detector can be engineered to suit individual requirements and weigh a wide range of flexible and rigid packs up to 6kg. Designed to survive even the harshest of manufacturing environments, it is constructed of stainless steel throughout. The electronics are said to guarantee optimum reliability and the flexible multifrequency detection ‘adapts to new products and packages within seconds’.

Loma will also show versions of its ‘flagship’ IQ3+ metal detector system, the IQ3+ Metal Detector Conveyor and the new IQ3+ PipeLine. The IQ3+ features increased immunity to vibration, electrical interference, case distortion and thermal shock. The conveyor is able to operate at any frequency between 40kHz and 900kHz, with the ability to select the correct operating frequency ‘in seconds’. The IQ3+ PipeLine is a metal detection system for pumped liquid and semi-liquid products, including diced, ground and chopped meat, dairy products, sauces, soups, jams and preserves.

Complementing the checkweighing and metal detection products on show, Loma will also display its X4 X-ray system. This is able to detect non-metallic contaminants and monitor weight, size and shape of products to maintain strict safety and quality control. When a contaminant is identified, the unit triggers immediate ejection of the product. The data relating to each detection and ejection are stored in an events memory.

The detector constantly monitors its detection characteristics, allowing continuous compensation for any variations arising from environmental factors. The control system is designed to manage all the functions required by the transport system, such as belt motor control, interfacing with barcode readers to identify products in real time, and ejection management including verification of successful ejection.

Ishida Europe (stand C80) will introduce a new ‘value for money’ checkweigher range. The DACS-W-012-N model incorporates Ishida’s advanced technology, includin DSP (Digital Signal Processing), to offer high speeds and ‘pinpoint accuracy’. Also on display with be a second model, featuring a colour touchscreen that provides easy to follow instructions for line operators, with online help, self-diagnostics and fault finding.

Both models support Ishida’s IDCS data capture software, which records information from every pack weighed by up to 100 checkweighers into a single secure database, providing a rich source of valuable production data. The reports generated can indicate, for example, how much product food manufacturers and packers are giving away in any given time period, or how often lines are not operating when they should. Companies can use the information to increase their line efficiencies by identifying the causes of downtime.

The detector has an exclusive Autolearn feature which optimises detection sensitivity for maximum speed and precision - equivalent to hundreds of conventional learning transits.

More on some of these detectors and checkweighers can be found in our Inspection Feature this month.


Tiny hooks mate to reclose the top of PFM’s Plix-Pack bag PFM Ilapak's Carrera 4000 horizontal packaging machine Ilapak Marden-Edwards showing Evo-Fold overwrapper Marden-Edwards

Ilapak Ilapak
PFM PFM
Marden-Edwards Marden-Edwards


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